EP1870389A2 - Extrusion or injection moding composition and method for preparing molded part - Google Patents
Extrusion or injection moding composition and method for preparing molded part Download PDFInfo
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- EP1870389A2 EP1870389A2 EP07011400A EP07011400A EP1870389A2 EP 1870389 A2 EP1870389 A2 EP 1870389A2 EP 07011400 A EP07011400 A EP 07011400A EP 07011400 A EP07011400 A EP 07011400A EP 1870389 A2 EP1870389 A2 EP 1870389A2
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- European Patent Office
- Prior art keywords
- water
- particles
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- extrusion
- cellulose
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- 238000001125 extrusion Methods 0.000 title claims abstract description 23
- 239000000203 mixture Substances 0.000 title claims abstract description 23
- 238000000034 method Methods 0.000 title claims description 19
- 238000002347 injection Methods 0.000 title 1
- 239000007924 injection Substances 0.000 title 1
- 239000002245 particle Substances 0.000 claims abstract description 49
- 239000011230 binding agent Substances 0.000 claims abstract description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 12
- 238000001746 injection moulding Methods 0.000 claims abstract description 10
- 239000012798 spherical particle Substances 0.000 claims abstract description 8
- 239000003232 water-soluble binding agent Substances 0.000 claims abstract description 8
- 239000000919 ceramic Substances 0.000 claims description 13
- 239000001866 hydroxypropyl methyl cellulose Substances 0.000 claims description 9
- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 claims description 9
- 235000010979 hydroxypropyl methyl cellulose Nutrition 0.000 claims description 9
- UFVKGYZPFZQRLF-UHFFFAOYSA-N hydroxypropyl methyl cellulose Chemical compound OC1C(O)C(OC)OC(CO)C1OC1C(O)C(O)C(OC2C(C(O)C(OC3C(C(O)C(O)C(CO)O3)O)C(CO)O2)O)C(CO)O1 UFVKGYZPFZQRLF-UHFFFAOYSA-N 0.000 claims description 9
- 229920000609 methyl cellulose Polymers 0.000 claims description 9
- 239000001923 methylcellulose Substances 0.000 claims description 9
- 235000010981 methylcellulose Nutrition 0.000 claims description 9
- 229920001479 Hydroxyethyl methyl cellulose Polymers 0.000 claims description 8
- 229920002153 Hydroxypropyl cellulose Polymers 0.000 claims description 7
- 239000001863 hydroxypropyl cellulose Substances 0.000 claims description 7
- 235000010977 hydroxypropyl cellulose Nutrition 0.000 claims description 7
- 239000011521 glass Substances 0.000 claims description 5
- LNAZSHAWQACDHT-XIYTZBAFSA-N (2r,3r,4s,5r,6s)-4,5-dimethoxy-2-(methoxymethyl)-3-[(2s,3r,4s,5r,6r)-3,4,5-trimethoxy-6-(methoxymethyl)oxan-2-yl]oxy-6-[(2r,3r,4s,5r,6r)-4,5,6-trimethoxy-2-(methoxymethyl)oxan-3-yl]oxyoxane Chemical compound CO[C@@H]1[C@@H](OC)[C@H](OC)[C@@H](COC)O[C@H]1O[C@H]1[C@H](OC)[C@@H](OC)[C@H](O[C@H]2[C@@H]([C@@H](OC)[C@H](OC)O[C@@H]2COC)OC)O[C@@H]1COC LNAZSHAWQACDHT-XIYTZBAFSA-N 0.000 claims description 4
- 229920000896 Ethulose Polymers 0.000 claims description 4
- 239000001859 Ethyl hydroxyethyl cellulose Substances 0.000 claims description 4
- 235000019326 ethyl hydroxyethyl cellulose Nutrition 0.000 claims description 4
- 229920013819 hydroxyethyl ethylcellulose Polymers 0.000 claims description 4
- 229920001059 synthetic polymer Polymers 0.000 claims description 4
- 238000005245 sintering Methods 0.000 claims description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052799 carbon Inorganic materials 0.000 claims description 2
- 238000000465 moulding Methods 0.000 abstract description 32
- 239000000758 substrate Substances 0.000 abstract description 11
- 238000001035 drying Methods 0.000 description 15
- -1 polyoxyethylene Polymers 0.000 description 13
- 238000006467 substitution reaction Methods 0.000 description 13
- 239000000463 material Substances 0.000 description 11
- 239000007864 aqueous solution Substances 0.000 description 9
- 239000000843 powder Substances 0.000 description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 7
- 229920003086 cellulose ether Polymers 0.000 description 5
- GAWIXWVDTYZWAW-UHFFFAOYSA-N C[CH]O Chemical group C[CH]O GAWIXWVDTYZWAW-UHFFFAOYSA-N 0.000 description 4
- NEHMKBQYUWJMIP-UHFFFAOYSA-N chloromethane Chemical compound ClC NEHMKBQYUWJMIP-UHFFFAOYSA-N 0.000 description 4
- 229910052878 cordierite Inorganic materials 0.000 description 4
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 125000000956 methoxy group Chemical group [H]C([H])([H])O* 0.000 description 4
- 238000005192 partition Methods 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 description 3
- 239000004354 Hydroxyethyl cellulose Substances 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 229920002678 cellulose Polymers 0.000 description 3
- 239000001913 cellulose Substances 0.000 description 3
- 229910010293 ceramic material Inorganic materials 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 239000008406 cosmetic ingredient Substances 0.000 description 3
- 235000014113 dietary fatty acids Nutrition 0.000 description 3
- 239000000194 fatty acid Substances 0.000 description 3
- 229930195729 fatty acid Natural products 0.000 description 3
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 3
- 239000012254 powdered material Substances 0.000 description 3
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 2
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 2
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- VAYGXNSJCAHWJZ-UHFFFAOYSA-N dimethyl sulfate Chemical compound COS(=O)(=O)OC VAYGXNSJCAHWJZ-UHFFFAOYSA-N 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000003631 expected effect Effects 0.000 description 2
- 229910052602 gypsum Inorganic materials 0.000 description 2
- 239000010440 gypsum Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 229940050176 methyl chloride Drugs 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000002861 polymer material Substances 0.000 description 2
- 229920002503 polyoxyethylene-polyoxypropylene Polymers 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- FFJCNSLCJOQHKM-CLFAGFIQSA-N (z)-1-[(z)-octadec-9-enoxy]octadec-9-ene Chemical compound CCCCCCCC\C=C/CCCCCCCCOCCCCCCCC\C=C/CCCCCCCC FFJCNSLCJOQHKM-CLFAGFIQSA-N 0.000 description 1
- 125000004066 1-hydroxyethyl group Chemical group [H]OC([H])([*])C([H])([H])[H] 0.000 description 1
- 229920002101 Chitin Polymers 0.000 description 1
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 description 1
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 1
- AFCARXCZXQIEQB-UHFFFAOYSA-N N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]-2-[[3-(trifluoromethoxy)phenyl]methylamino]pyrimidine-5-carboxamide Chemical compound O=C(CCNC(=O)C=1C=NC(=NC=1)NCC1=CC(=CC=C1)OC(F)(F)F)N1CC2=C(CC1)NN=N2 AFCARXCZXQIEQB-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- JRPBQTZRNDNNOP-UHFFFAOYSA-N barium titanate Chemical compound [Ba+2].[Ba+2].[O-][Ti]([O-])([O-])[O-] JRPBQTZRNDNNOP-UHFFFAOYSA-N 0.000 description 1
- 229910002113 barium titanate Inorganic materials 0.000 description 1
- 239000005388 borosilicate glass Substances 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 239000008151 electrolyte solution Substances 0.000 description 1
- RTZKZFJDLAIYFH-UHFFFAOYSA-N ether Substances CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 150000004676 glycans Chemical class 0.000 description 1
- 235000011187 glycerol Nutrition 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 125000001165 hydrophobic group Chemical group 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000005355 lead glass Substances 0.000 description 1
- HFGPZNIAWCZYJU-UHFFFAOYSA-N lead zirconate titanate Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[Ti+4].[Zr+4].[Pb+2] HFGPZNIAWCZYJU-UHFFFAOYSA-N 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 229920001515 polyalkylene glycol Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000259 polyoxyethylene lauryl ether Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920001451 polypropylene glycol Polymers 0.000 description 1
- 229920001282 polysaccharide Polymers 0.000 description 1
- 239000005017 polysaccharide Substances 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 239000000600 sorbitol Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/0006—Honeycomb structures
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/22—Expanded, porous or hollow particles
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C12/00—Powdered glass; Bead compositions
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L1/00—Compositions of cellulose, modified cellulose or cellulose derivatives
- C08L1/08—Cellulose derivatives
- C08L1/10—Esters of organic acids, i.e. acylates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/24—Producing shaped prefabricated articles from the material by injection moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00034—Physico-chemical characteristics of the mixtures
- C04B2111/00129—Extrudable mixtures
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/0081—Uses not provided for elsewhere in C04B2111/00 as catalysts or catalyst carriers
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/2084—Thermal shock resistance
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Organic Chemistry (AREA)
- Materials Engineering (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Structural Engineering (AREA)
- Polymers & Plastics (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Life Sciences & Earth Sciences (AREA)
- General Chemical & Material Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Detergent Compositions (AREA)
Abstract
Description
- This invention relates to an extrusion or injection molding composition for producing a molded part of the desired shape from a powder of the desired material, and a method for preparing a molded part using the composition.
- In general, molded parts of the desired shape are produced by molding a powdered material and a binder into the desired shape so that the binder exerts a sufficient binding force to sustain the shape. In molding ceramics in this way, molded parts are sintered while effecting binder removal.
- Depending on the desired shape to be molded, an appropriate molding technique may be selected from among a molding technique of mixing a powdered material with a binder and press molding the mixture, and a molding technique of dissolving a binder in a solvent, mixing a powdered material with the solution, sheeting the mixture to a desired thickness in the case of a sheet-like form, and evaporating off the solvent. Also, parts of more complex shape may be molded by a technique of casting a similar slurry into a mold of gypsum or the like, removing the solvent through micro-pores in the gypsum mold surface while molding, and drying to the desired shape, or an injection molding technique of injecting a body composed of a mixture of a solvent solution of a binder having a viscosity and shape-retaining ability and a desired powder material into an appropriate mold, transferring the mold shape thereto, and drying. An extrusion molding technique is also employed wherein honeycomb-shaped parts or parts of a certain cross-sectional shape such as plates or rods are molded by passing a similar body through an extrusion die having exit channels of lattice-like slits and feed channels for feeding the body to the crossings of the slits.
- Although the ceramic material molding techniques described above facilitate casting or flowing of a desired material into a mold, it is essential to add a binder for binding the powder material or substrate after drying because the molded material must be dried while maintaining the shape of the mold after casting. In a common practice, a proper binder is selected so as to maintain the shape during the drying step after molding. If a binder having a strong binding force is used to stabilize the shape during the drying step, the resulting body becomes less flowing, making it difficult to fill the mold therewith. If a binder having a weak binding force is used to overcome this problem, then the shape can collapse or cracks can occur in the drying course after molding.
- For overcoming the above-discussed problems, for example,
JP-A 04-209747 JP-A 06-092715 JP-A 07-138076 Japanese Patent No. 2756081 Japanese Patent No. 2756081 JP-A 2001-179720 - An object of the present invention is to provide an extrusion or injection molding composition comprising substrate particles and a binder, from which a part is to be molded, which is improved in fluidity during molding, while maintaining a shape-retaining ability after molding and which enables such molding with a minimal amount of the binder added; and a method for preparing a molded part using the composition.
- The inventors have found that the outstanding problems can be overcome using true spherical particles having a specific particle size.
- In one aspect, the invention provides an extrusion or injection molding composition comprising water-insoluble particles, a water-soluble binder, and water. The water-insoluble particles are true spherical particles having an average particle size of 0.2 to 20 µm.
- In a preferred embodiment, the composition comprises 100 parts by weight of the water-insoluble particles, 2 to 10 parts by weight of the water-soluble binder, and 5 to 40 parts by weight of water. Typically, the true spherical particles are water-insoluble ceramic particles, glass particles or carbon-containing synthetic polymer particles. The water-soluble binder is typically selected from among water-soluble methyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl methyl cellulose, hydroxyethyl ethyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose. Most often, the composition is extrusion molded into a honeycomb structure.
- In another aspect, the invention provides a method for preparing a molded part consisting of water-insoluble particles, the method comprising the steps of extrusion or injection molding the above-described composition into a green part, effecting binder burnout, and sintering the green part.
- According to the invention, the use of water-insoluble true spherical particles as the substrate, despite a small amount of a binder added, facilitates molding operation and enables to produce a molded part featuring a shape stability after molding.
- True spherical water-insoluble particles used herein should have an average particle size of 0.2 to 20 µm, preferably 0.3 to 18 µm, and more preferably 0.5 to 15 µm. Particles with a smaller particle size outside the range will agglomerate significantly so that the desired effects of the invention are not expectable. Particles with a larger particle size outside the range are less flowing so that the effect of improving flow during molding is not expectable.
- As used herein, the average particle size of particles is measured by a Coulter Counter by Beckman Coulter Inc. operating on an electrical sensing zone method in a special electrolyte solution.
- The water-insoluble particles used herein are true spherical particles having a degree of true sphericity equal to or less than 1.1. The degree of true sphericity is the "average degree of true sphericity" described in
JP-A 06-64916 - Specifically, an average degree of true sphericity is determined by taking a photograph of substrate particles under an optical or electron microscope, determining a ratio of maximum diameter to minimum diameter for each of 100 particles, and calculating an average thereof. A particulate powder having an average value equal to or less than 1.1, preferably equal to or less than 1.05 is used herein. A powder with an average value in excess of 1.1 will form a body which is not improved in flow.
- No particular limit is imposed on the particle size distribution of a particulate powder although a powder having a certain distribution is advantageous in improving the shape-retaining ability after molding.
- The water-insoluble particles used herein as the substrate powder may be made of ceramic materials, glass materials, and synthetic polymer materials. Suitable ceramic materials include, but are not limited to, cordierite materials, alumina, mullite, silica, silicon carbide, silicon nitride, titanium oxide, barium titanate, and lead titanate zirconate. Suitable glass materials include, but are not limited to, quartz glass, soda glass, borosilicate glass, and lead glass. Suitable synthetic polymer materials include, but are not limited to, polystyrene, polypropylene, polyethylene, methyl methacrylate, and polyurethane. Also useful are water-insoluble natural polysaccharides such as cellulose and chitin.
- The inventive composition comprises a water-soluble binder. Suitable binders include cellulose ethers and polyoxyethylene-polyoxypropylene surfactants. Inter alia, methyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl methyl cellulose, hydroxyethyl ethyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose, which have a greater shape-retaining ability after molding, are advantageous for the invention to exert its effects to a full extent.
- The methyl cellulose which can be used herein is one prepared by a methyl chloride or dimethyl sulfate method and having a methoxy substitution of 26-33% by weight and a viscosity of 25-30,000 mPa-s at 20°C in a 2 wt% aqueous solution, as described in Cosmetic Ingredient Standards Remarks, Yakuji-Nippo K.K., 1984, p.1146. The hydroxyethyl cellulose which can be used herein is one prepared by reacting ethylene oxide with cellulose and having a hydroxyethyl substitution of 40-60% by weight and a viscosity of 20-100,000 mPa-s at 20°C in a 2 wt% aqueous solution, as described in Cosmetic Ingredient Standards Remarks, Yakuji-Nippo K.K., 1984, p.840. The hydroxypropyl cellulose which can be used herein is one prepared by reacting propylene oxide with cellulose and having a hydroxypropyl substitution of 50-70% by weight and a viscosity of 50-10,000 mPa-s at 20°C in a 2 wt% aqueous solution, as described in Cosmetic Ingredient Standards Remarks, Yakuji-Nippo K.K., 1984, p.849.
- Mixed ethers such as hydroxypropyl methyl cellulose and hydroxyethyl methyl cellulose can be prepared by reacting ethylene oxide or propylene oxide in addition to methyl chloride or dimethyl sulfate during the methyl cellulose preparation. Use may be made of hydroxyethyl methyl cellulose and hydroxypropyl methyl cellulose having a degree of substitution of 19-30% by weight for methyl and 4-12% by weight for hydroxyethyl or hydroxypropyl and a viscosity of 50-200,000 mPa-s at 20°C in a 2 wt% aqueous solution. The degree of substitution and viscosity can be measured by the methods described in the Japanese Pharmacopoeia, 14th Edition. Those cellulose ethers having a degree of substitution outside the above-defined range may be short in water solubility and fail to produce a sufficient binding force upon drying of a molded ceramic part. Too low a viscosity may lead to a shortage of binding force whereas with too high a viscosity, the resulting body may be too viscous to extrusion mold.
- According to the invention, at least one binder selected from among methyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl methyl cellulose, hydroxyethyl ethyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose is added preferably in an amount of 2 to 10 parts by weight, more preferably 3 to 8 parts by weight per 100 parts by weight of the water-insoluble particles (or substrate powder). If the amount of cellulose ether added is less than 2 parts by weight, the shape-retaining ability declines so that the molded part may deform under its own weight or external force. If the amount of cellulose ether added is more than 10 parts by weight, cracks are likely to occur upon binder burn-out by heating after molding and drying.
- In the inventive composition, water is added preferably in an amount of 5 to 40 parts by weight, more preferably 6 to 30 parts by weight per 100 parts by weight of the water-insoluble particles. Too small an amount of water added may detract from moldability or lubricity. If the amount of water added is excessive, the article may lose dimensional accuracy due to separation of water during extrusion and shrinkage during drying.
- If necessary, derivatives of glycol, glycerin, polyoxyethylene, polyoxypropylene, sorbitol and the like, and surfactants such as fatty acid esters and fatty acid salts may be added to the inventive composition as long as this does not compromise the objects of the invention.
- In producing a molded part of desired shape from the extrusion or injection molding composition of the invention, conventional extrusion and injection molding techniques may be applied, and well-known molding conditions be employed. The molding is followed by binder burn-out and sintering, obtaining a molded part consisting of water-insoluble particles.
- The shape of molded parts is not particularly limited. The invention is effective in producing molded parts of honeycomb structure, especially extrusion molded parts.
- Examples are given below by way of illustration and not by way of limitation.
- To 100 parts by weight of alumina particles having an average particle size of 0.4 to 13 µm and a degree of true sphericity of 1.01 to 1.04, available from Admatechs Co., Ltd., as shown in Table 1, were added 2.0 to 10.0 parts by weight of cellulose ether shown in Table 1 and water in the amounts shown in Table 1. They were mixed in a Super-Mixer (Kawada Mfg. Co., Ltd.) by operating an agitation blade at 1,000 rpm and then at 15°C on a compact three-roll mill (Inoue Mfg. Co., Ltd.). The resulting compound was extrusion molded into a green honeycomb structure, using a laboratory honeycomb extrusion molding machine (Miyazaki Iron Works Co., Ltd.) with a honeycomb die having a rib gage of 0.2 mm, a rib spacing of 5 mm, and a diameter of 20 mm. It was dried at 100°C for 16 hours. After drying, the honeycomb structure was heated at 500°C for 2 hours for binder burn-out and sintered in an electric furnace at 1,700°C.
- In all the molding runs of Examples 1 to 9 shown in Table 1, there were obtained ceramic honeycomb structure samples in which neither waving of partitions or ribs during molding, especially waving of partitions near the outer periphery, nor cracking during the drying step after molding occurred.
Table 1 Example 1 2 3 4 5 6 7 8 9 Alumina, average particle size (µm) 0.4-1.0 7-13 2-8 0 4-1.0 7-13 2-8 0.4-1.0 7-13 2-8 Alumina, average degree of true sphericity 1.04 1.08 1.05 1.06 1.08 1.09 1.04 1.09 1.03 Methyl cellulose 3 3 2 Hydroxypropyl methyl cellulose 2 2 1 Hydroxyethyl methyl cellulose 5 Hydroxyethyl cellulose 7 1 Polyoxyethylene polyoxypropylene butyl ether 10 2 Hydroxypropyl cellulose 2 Water 22 25 23 24 22 23 21 20 19 - Note that the amount of each component added is expressed in parts by weight per 100 parts by weight of alumina.
- Methyl cellulose:
- methoxy substitution, 30 wt%
- viscosity @20°C/2 wt% aqueous solution, 4,000 mPa-s
- Hydroxypropyl methyl cellulose:
- methoxy substitution, 29 wt%
- hydroxypropyl substitution, 10 wt%
- viscosity @20°C/2 wt% aqueous solution, 200,000 mPa-s
- Hydroxyethyl methyl cellulose:
- methoxy substitution, 29 wt%
- hydroxyethyl substitution, 10 wt%
- viscosity @20°C/2 wt% aqueous solution, 100,000 mPa-s
- Hydroxyethyl cellulose:
- hydroxyethyl substitution, 55 wt%
- viscosity @20°C/2 wt% aqueous solution, 4,000 mPa-s
- Hydroxypropyl cellulose:
- hydroxypropyl substitution, 60 wt%
- viscosity @20° C/2 wt% aqueous solution, 4,000 mPa-s
- In these examples, the compounds of Examples 1 to 9 were extrusion molded through a honeycomb die having a rib gage of 0.1 mm, a rib spacing of 4 mm, and a diameter of 20 mm, into honeycomb structures and dried at 100°C for 16 hours. After drying, the honeycomb structures were heated at 500°C for 2 hours for binder burn-out and sintered in an electric furnace at 1,700°C.
- In all the molding runs of Examples 10 to 18, there were obtained ceramic honeycomb structure samples in which neither waving of partitions during molding, especially waving of partitions near the outer periphery, nor cracking during the drying step after molding occurred.
- The molding runs of Examples 1 to 3 were repeated except that the substrate was replaced by alumina particles having an average particle size of 0.4 µm and a degree of true sphericity of 1.3 to 1.7, available from Showa Light Metal Co., Ltd. The molded parts had a poor shape-retaining ability, and many cracks occurred upon drying.
- The molding runs of Examples 1 to 3 were repeated except that the substrate was replaced by alumina particles having an average particle size of 10 µm and a degree of true sphericity of 1.8 to 2.7, available from Nippon Light Metal Co., Ltd. The molded parts had a poor shape-retaining ability, and many cracks occurred upon drying.
- The data of Examples and Comparative Examples demonstrates the benefits of the invention.
Claims (6)
- An extrusion or injection molding composition comprising water-insoluble particles, a water-soluble binder, and water, wherein said water-insoluble particles are true spherical particles having an average particle size of 0.2 to 20 µm.
- The composition of claim 1, comprising 100 parts by weight of the water-insoluble particles, 2 to 10 parts by weight of the water-soluble binder, and 5 to 40 parts by weight of water.
- The composition of claim 1 or 2, wherein said true spherical particles are water-insoluble ceramic particles, glass particles or carbon-containing synthetic polymer particles.
- The composition of claim 1, 2 or 3, wherein said water-soluble binder is selected from the group consisting of water-soluble methyl cellulose, hydroxypropyl methyl cellulose, hydroxyethyl methyl cellulose, hydroxyethyl ethyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose.
- The composition of any one of claims 1 to 4, which is to be extrusion molded into a honeycomb structure.
- A method for preparing a molded part consisting of water-insoluble particles, the method comprising the steps of extrusion or injection molding the composition of any one of claims 1 to 5 into a green part, effecting binder burnout, and sintering the green part.
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EP (1) | EP1870389A3 (en) |
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WO2011136979A1 (en) * | 2010-04-26 | 2011-11-03 | Dow Global Technologies Llc | Composition for extrusion-molded bodies |
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Also Published As
Publication number | Publication date |
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CN101089035A (en) | 2007-12-19 |
TW200817304A (en) | 2008-04-16 |
US20070293387A1 (en) | 2007-12-20 |
KR20070119544A (en) | 2007-12-20 |
EP1870389A3 (en) | 2011-03-16 |
JP2007331978A (en) | 2007-12-27 |
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